• 2005-2010 Mustang GT BBK Long Tube Headers - Chrome (BBK 1641)
• 2005-2010 Mustang GT BBK Long Tube Headers - Stainless Steel (BBK 16415)
• 2005-2010 Mustang GT BBK Long Tube Headers - Silver Ceramic (BBK 16410)

BBK's Long Tube Headers come with:

Two oxygen sensor extensions, two header gaskets, 16 header bolts, four collector studs, four collector nuts, four washers, four lock washers

Tools you will need:

Jack and jack stands, wood blocks; ratchet, ratchet extensions and universal joint swivel, 5mm, 7mm, 8mm, 10mm, 13mm, 15mm sockets, 13mm deep socket, 5mm and 13mm wrenches; flat head screwdriver, crescent wrench

Using the 8mm socket, disconnect the negative (-) battery terminal.

Remove the dipstick tube:

Using the 7mm socket, unbolt the bracket that holds the dipstick and remove the dipstick from the engine bay.

Jack up the car and support it with jack stands.

Unplug all 4 oxygen sensors:

There are three oxygen sensors underneath your Mustang, on the H-pipe. The last oxygen sensor is located on the driver's side exhaust manifold.

Press down on the tab and slide apart to unplug oxygen sensors.

Remove your Mustang's stock H-pipe:

Use the 15mm socket to loosen the nuts on the clamp bands that hold the H-pipe to the cat-back exhaust.

Use the small flat screwdriver to pry the locking tabs up and slide the H-pipe towards the front of the car, away from the cat-back exhaust.

Use the 13mm socket to unbolt the other end of the H-pipe from your Mustang's stock exhaust manifolds.

Remove the H-pipe from the car.

Remove the oxygen sensors from your Mustang's stock H-pipe:

Use the crescent wrench to remove the three oxygen sensors.

It's a good idea to label the oxygen sensors so that you will know where to install them on your aftermarket short mid-pipe.

Remove the steering shaft:

Use the 13mm socket to remove the bolts that hold the steering shaft in place.

Remove the top joint:

Get inside the your Mustang and retract the steering shaft. Grab the steering shaft as it enters the fire wire and pull off the top joint.

The bottom should come out easily with the top off.

Remove the driver's side motor mount:

Remove the nut on the stud that holds the motor mount to the K-member.

Carefully jack up the motor, supporting it with a block of wood. Place the wood block right behind the bottom pulley on the bolts that hold the oil pan on, but NOT on the oil pan itself. Do NOT jack up the motor more than a few inches!

Use the 13mm socket to remove the four bolts that secure the motor mount to the engine.

Remove the motor mount.

Remove your Mustang's driver side stock exhaust manifold:

Unbolt the 8 nuts holding the exhaust manifold to the engine.

Remove the 8 exhaust manifold studs.

Remove the exhaust manifold and gasket from the engine.

Remove the oxygen sensor from the stock exhaust manifold and install it on your new BBK driver side header, install the supplied collector studs on your BBK headers:

Use a crescent wrench to remove the oxygen sensor the stock exhaust manifold.

Install the oxygen sensor in your BBK long tube header with the crescent wrench.

Install the supplied collector studs on your BBK headers. The shorter threaded end of the supplied collector studs goes into the header. Hand tighten the collector studs.

Install your BBK header and gasket on the driver's side of your Mustang:

Put the supplied bolts through the bolt holes in the header and put the gasket on. The bolts will help guide the header to the bolt holes in the engine block.

Install the header and hand-tighten the bolts. Once all the bolts are hand-tightened and the header is properly aligned, tighten down the header bolts with a ratchet.

Reinstall the driver side motor mount, dipstick tube, and steering shaft:

You may someone to hold the steering wheel in place in order to re-install the steering shaft.

Remove starter:

Disconnect electrical connections from starter.

Unbolt and remove starter from the bell housing.

Remove passenger side motor mount:

See step 8.

Remove stock exhaust manifold and gasket.

Install your new BBK long tube header.

Note: In some cases it may be easier to re-use some of the stock hardware instead of using the supplied hardware.

Re-install starter and passenger side motor mount.

Lower motor mounts onto studs and tighten nuts.

Install your aftermarket shorty mid-pipe :

Use supplied washers, lock washers, and nuts on the collector studs.

Note: For best fitment you should use BBK's shorty X-pipe either BBK part # 1636 or 1637.

Install oxygen sensors on your shorty mid-pipe, connect oxygen sensors:

Use the oxygen sensor extenders between the oxygen sensor and the stock oxygen sensor wiring harnesses.

Reconnect negative (-) battery terminal.

Note: It's a good idea to check and re-tighten the header bolts after driving a few miles.